Ok, I am at a loss, I have on 03 Evo 8, 3 months ago we rebuilt the trans and replaced pretty much everything inside. Bearings, all syncros, sliders, all syncro gears, new input shaft, new clutch, pressure plate, flywheel, seals and etc. couple days of driving after rebuild it starts grinding in 3rd doesn't matter what RPM after that started a month or so later it started slipping out of gear on 4th not all the time but sometimes. Opened her back up replaced shims, thruster place and make sure they were to the spec of the trans, replaced 3rd again, synco and slider because of damage. Closed her up. Still having the same problem. It almost like there is too much space on the input shaft. Like the gears are sliding. But literally everything on the input shaft is OEM brand new and purchased from either Mitsubishi dealership or jacks trans. Thoughts?

 

If you are using the correct Parts from Mitsu from latest bulletin and following the latest manual and setting ur preloads and shimming correctly then it could be bad or wrong shifter bushings or mounts or something in that nature, maybe u have too much preload on ur shifter line? Maybe? Maybe installed it incorrectly maybe used a washer in the shift shaft or shifter bracket or in the shifter itself or a bad shifter cable? Does it pop out a gear at a certain rpm? What fluids? Was clutch installed properly? Did u magnaflux ur gears n shafts prior installation.

 

Im assuming its the set that has the slider removed?

The bottom teeth look worn crooked and might be why the slider isnt fully locking. Idk what the parts are named but. The teeth under the lower synchro. Take a closer pic of them.

 

Redline mt90 first time now Amsoil, any RPM on 3rd. So when I shift into 3rd the only time I can get it to go in smoothly is clutch in shift half way, I feel the 3rd gear move and almost "hit" back pushing me out slightly then I can go in smoothly. Any other way and it grinds. We used all data on the trans rebuild. I am pretty sure it something to do with the input shaft. I have been thinking maybe one of the gears is wrong and it's creating to much space. But would the wrong gear even fit and run on he Evo. And we had a master mitsu tech how does these all the time help us the first time and we ran into the same problem.

 

That gap above 5th is that normal?

 

Also occasionally she has a hard time shift in to gear from a stop. Once she ins warmed up, it doesn't happen all the time, every once in a while and I have to pump on the clutch several times and then it goes in. I can always eventually get it in sometimes take jsutban extra 5 seconds. I think this is a seperate issue tho.

 

There is another thread from yesterday if I recall about a guy who switched trans fluid to amsoil and is having the same problem but in 5th gear... should be on this sub forum category or in general although I don't think that's the problem, give Teamrip.com a call. (TRE)
The gear not engaging sounds like clutch drag, and that will eat up the synchros.

 

This is the husband. I put everything onto the input shaft as instructed following the manual. The only difference I notice in gear play was when I flipped flip speed gear upside down everything was tight, but then i couldn't get the cap on top of the thruster plate. Should I have tried it that way and taped the cap onto the thruster plate? Besides input shaft excessive gear play I am now having trouble shifting into any gear after stopping ata light. It a hit or miss but it was frequent when I drove it.

 

Its kinda hard to put a set upside down. Yea you can do it but you woouldnt be able to finish the gear stack. Something along the lines after the upside down gear would not sit right or clip on. The gear stacks are kinda designed to only go 1 way.